The
following should work on any removeable throttle body. This is a 3.0 Throttle
body off a 2004 Ranger. We dissassembled a 2004 4.0 throttle body and the
steps were identical to this. First remove the throttle body from the truck.
Remove the two screws holding the round disc in the center of the throttle body. Open the throttle body and slide the disc out. Note the position for reinstalling. Remove the two screws on the electronic device on the right and remove the device.
With those pieces removed, you can slide out the shaft. Make note of the spring position so it can be reinstalled.
Next I used an electric grinder with a metal cutoff wheel to cut out the shaft. DO NOT remove the section that is threaded. Remove the side that is an open hole. I left a little of the slot on each side. Clean the cut with a file or grinding wheel.
Make sure there is no metal shavings or debri before reassembly. I used an air gun to thoroughly blow out all pieces. Slide the shaft back in just enough to position both sides of the spring. Spin the shaft a couple of times to preload the spring, then push the rest of the way in. Reattach the electronic device. Rotate the shaft to slide the disc back in and slowly turn it back to closed. There should be no gaps or daylight through the disc. Reattach the two screws holding the disc. I failed to take a "before" picture, but the original obstruction was close to double the size pictured.
Lastly, we used a die grinder to shaved the threads of the screws flush with the shaft.
I have used this tool in the past to taper bore the throttle body. It is a cylinder honing tool and is available at Sears and many Auto Parts stores. I attach it to a cordless drill and insert it into the throttle body using a gentle up and down motion to bore out the throttle body. DO not get near the disc seating area. If you enlarge this area you will have major idle problems on the vehicle. The goal is to enlarge the opening where the intake tube attaches and gradually taper this back down to oem size before the disc.
It's a relatively simple mod and is basically free. It took about an hour. We were able to get a used throttle body in case there were problems, but it ended up not being necessary. The benefit is one less obtruction in the air path to the cylinders.
Remove the two screws holding the round disc in the center of the throttle body. Open the throttle body and slide the disc out. Note the position for reinstalling. Remove the two screws on the electronic device on the right and remove the device.
With those pieces removed, you can slide out the shaft. Make note of the spring position so it can be reinstalled.
Next I used an electric grinder with a metal cutoff wheel to cut out the shaft. DO NOT remove the section that is threaded. Remove the side that is an open hole. I left a little of the slot on each side. Clean the cut with a file or grinding wheel.
Make sure there is no metal shavings or debri before reassembly. I used an air gun to thoroughly blow out all pieces. Slide the shaft back in just enough to position both sides of the spring. Spin the shaft a couple of times to preload the spring, then push the rest of the way in. Reattach the electronic device. Rotate the shaft to slide the disc back in and slowly turn it back to closed. There should be no gaps or daylight through the disc. Reattach the two screws holding the disc. I failed to take a "before" picture, but the original obstruction was close to double the size pictured.
Lastly, we used a die grinder to shaved the threads of the screws flush with the shaft.
I have used this tool in the past to taper bore the throttle body. It is a cylinder honing tool and is available at Sears and many Auto Parts stores. I attach it to a cordless drill and insert it into the throttle body using a gentle up and down motion to bore out the throttle body. DO not get near the disc seating area. If you enlarge this area you will have major idle problems on the vehicle. The goal is to enlarge the opening where the intake tube attaches and gradually taper this back down to oem size before the disc.
It's a relatively simple mod and is basically free. It took about an hour. We were able to get a used throttle body in case there were problems, but it ended up not being necessary. The benefit is one less obtruction in the air path to the cylinders.